EP0204619B1

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Info

Publication number: EP0204619B1
Application number: EP19860401136
Authority: EP
Inventors: Bernard Doremus; Dale E. Meek
Original assignee: Schlumberger Technology Corp
Current assignee: Schlumberger Technology Corp
Priority date: 1985-05-31
Filing date: 1986-05-29
Publication date: 1990-12-05
Anticipated expiration: 2006-05-29
Also published as: CA1260384A; US4658904A; NO176774C; NO176774B; EP0204619A2; EP0204619A3; NO862063L

Description

This invention relates generally to a control valve apparatus that is positioned within a subsea blowout preventer stack during production testing of an offshore well, and particularly to a new and improved control valve apparatus that has remotely operable, redundant shut-in valves mounted in a short-length valve body, and a retainer valve that is incorporated as an integral part of a control unit that is releasably latched to the valve body.
To conduct a production test of an offshore well from a floating vessel, it has become conventional practice to employ a subsea master valve apparatus, or "test tree", that includes a relatively short-length valve body which is releasably latched to a hydraulically operable control unit. The apparatus is positioned and landed in a subsea blowout preventer stack that is located on the sea floor. The master valve section is connected to a production string of pipe that extends downwardly into a well, and the control unit is connected to a length of production pipe that extends upwardly within a riser to the floating vessel. Examples of related devices of this general type are shown in U.S. Patent Nos. 3,967,647 and 3,955,623, assigned to the assignee of this invention. These devices have the significant advantage over other systems, shown for example in U.S. Patent No. RE 27,464, that the hydraulic control unit can be disconnected from the valve body in case of an emergency, and removed with the pipe from the riser, leaving the valve body in place. The valve body houses upper and lower valve elements to provide redundant shut-in valves, with the upper valve being a normally closed flapper element and the lower valve being a normally closed ball element. Both valves are opened in response to pressurization of a control line that leads to the control unit, and are automatically closed whenever the control unit is unlatched and released from the valve body. The valve functions to shut-off the production string against upward flow of well fluids. The relatively short length of the valve body enables blind rams of the blowout preventer stack to be closed against one another at a location above the upper end of the valve body to ensure complete control of the well, and there are no exposed hydraulic connections or the like which would otherwise be subject to contamination by sea water or drilling fluids.
It also is well known to provide a "retainer" valve in the production string above the control unit. This valve, which is a normally open device, functions when closed in response to the pressure applied to a control line at the surface, to accelerate the disconnection of the control unit and valve body by suppressing the requirement to bleed of pressure in the upper production pipe. The retainer also enables pressure testing of the upper pipe for leaks prior to well testing. The retainer valve is of particular importance when testing in deep water because it can be closed to prevent pollution and dumping of high pressure gases within the riser.
The use of a separately positioned retainer valve has in the past required the presence of separate sets of hydraulic control lines for operating the master valves and the retainer valve. This requirement has resulted in complex hydraulic systems which are somewhat complicated for an operator to manipulate. Moreover, since the retainer valve has been positioned well above the control unit, a volume of well fluids and/or gases could still be dumped in the interior of the riser when the control unit is disconnected. In accordance with the present invention, the retainer valve system is an integral part of the control unit and is actuated in response to hydraulic pressures applied thereto. This construction greatly simplifies the overall arrangement of the tool and its operational sequence.
Another shortcoming of prior devices results from the fact that it is possible to trap fluids under pressure in the region between the shut-in valve and the retainer valve, which is undesirable for various reasons. One feature of the present invention lies in the provision of a bleed valve to vent pressure from this region, with the bleed valve being opened in response to a control pressure which causes release of the latch, and which opens prior to disconnection. The bleed valve cannot be opened so long as there is a control pressure being applied to maintain the shut-in valve open, and it is designed for fail-safe closure in response to well pressure. In case of hydraulic failure, the bleed valve can be opened mechanically when actuating an emergency mechanical means to disconnect the latch.
Another feature of the present invention is the provision of a ball valve element that closes fail-safe under the influence of both a spring and the pressure of a yieldable medium such as nitrogen gas. Closing also is assisted by well pressure, and the hydraulic pressure applied to a control line. The ball valve is opened, and held open, by hydraulic pressure applied to a separate control line, and is designed such that if opening pressure is lost, closure of the ball valve is provoked.
Still another feature of the new and improved subsea master valve of the present invention is the use of passages and ports within various structural members such that any fluid that leaks past a dynamic seal that is exposed to well pressure (a seal that moves relatively along another member when the tool is operated) will cause the system to assume a safe condition with the shut-in ball element closed. This feature provides additional assurance that the well will at all times be under control.
In accordance with a first aspect of the invention an apparatus adapted to be landed in a subsea wellhead is provided as defined in claim 1.
In accordance with another aspect of the invention, a method for use in the production testing of a well is also provided as defined inclaim 17.
The present invention has other objects, features and advantages which will become more closely apparent in connection with the following detailed description of preferred embodiments, - taken in conjunction with the appended drawings in which:

Fig. 1 is a schematic view of an offshore well installation in which a production test is being performed from a floating vessel;
Fig. 2 is a generalized longitudinal cross-sectional view of a control valve apparatus that is constructed in accordance with the present invention;
Fig. 3 is a top view of the valve apparatus of Fig. 2 showing connection for the various hydraulic control and other lines that extend upward to the vessel;
Figs. 4A and 4B are right-side-only, longitudinal cross-sectional views of one embodiment of the present invention, Fig. 4B forming a lower continuation of Fig. 4A;
Figs. 5A-5C are views similar to Figs. 4A and 4B of another embodiment of the present invention;
Fig. 6 is a developed plan view of a pin and slot system used in actuation of valves in the embodiment shown in Figs. 4A and 4B;
Figs. 7 and 8 are respective side and front views of the ball valve elements employed in the embodiment illustrated in Figs. 5A-5C; and
Fig. 9 is a front view of a yoke used to actuate the ball valve of Figs. 7 and 8.

Referring initially to Fig. 1, a floatingdrilling vessel 10 is shown stationed over anoffshore well 11. Acasing head assembly 12 that includes a landing base is fixed to the top of thewell casing 13, and is connected in an appropriate manner to ablowout preventer stack 14. Thestack 14 includes a plurality of ram-type preventers 15 having laterally movable rams that function when closed to shut off the annulus between the casing and a production string oftubing 16 that extends downwardly into the well. Anannular blowout preventer 17 typically is mounted on top of the ram-type preventers 15, and amarine riser 18 is connected by aball joint 19 to the top of thestack 14. Theriser 18 extends upward to a point above the water surface where it is coupled to thevessel 10 by a tensioning system (not shown). Various hydraulic lines and the like extend from onboard control panels down to theblowout preventer stack 14 in order to enable hydraulic actuation of the various components thereof in a well known manner.
Acontrol valve apparatus 20 that is constructed in accordance with the present invention is positioned inside theblowout preventer stack 14. The lower end of theapparatus 20 includes a shut-invalve section 21 that is connected by aslick joint 22 to afluted hanger flange 23 which is sized to rest upon ashoulder surface 24 at the lower end of thestack 14. The rams of the lower blowout preventer can be closed against theslick joint 22, and theflange 23 provides support for theproduction string 16. Acontrol unit 25 is releasably connected to the top of thevalve section 21, and contains various hydraulically controlled actuators and other mechanisms to enable opening and closing the valves in the system, as well as performing other functions as will be described in greater detail below. The upper end of thecontrol unit 25 is connected to apipe section 26 that extends upwardly within theriser 18 to a flow-head 27 onboard thevessel 10, and ahydraulic hose bundle 28 wound on areel 29 extends downwardly along thepipe 26 to the control unit for operating the same. Acontrol panel 30 is provided with suitable valves and associated equipment so that an operator can control the downhole equipment as desired.
Alubricator valve 31 can be coupled into thepipe string 26 at an appropriate level in the riser to enable the upper portion of the pipe string below the flow head to be used as a lubricator chamber during wireline operations so that tools can be run in, and removed from, the tubing under pressure.Centralizers 32 and 43 can be used to center the valve and control unit assembly within the bore of theblowout preventer stack 14 in a typical manner.
Referring to Fig. 2, thecontrol unit 25 includes, generally, anupper sub 40 that is threaded to anupper housing section 41, which is, in turn, threaded to alower housing section 42. Theupper housing section 41 can mount acentralizer ring 43, and a plurality of hydraulic hose connections are provided in a top surface of thesection 41 as shown in Fig. 3. A total of five such connections may be provided, including a line A connection through which hydraulic fluid under pressure is fed to cause opening of the main valves mounted in thesection 21, a line B connection through which hydraulic pressure is applied to assist in closing such main valves, as well as closing a retainer valve that is situated in the upper end of thecontrol unit 25 in accordance with one feature of the present invention, and a line C connection through which hydraulic pressure is applied to cause release of a latch system that connects thecontrol unit 25 to thevalve section 21. Anotherline connection 45 may be provided which enables injection of a chemical, such as hydrate inhibitor, into the flow passage through the apparatus at a location within thevalve section 21. Yet anotherline connection 46 can be provided which communicates with a passage that extends through thecontrol unit 25, thevalve section 21, the slick joint 22, and the hanger flange to a downhole point where a surface controlled,subsurface safety valve 47 is located in theproduction pipe string 16.
Referring again to Fig. 2, a retainer valve in the form of aflapper element 50 is hinged to a seat ring 51 and arranged to close downwardly thereagainst. Theflapper element 50 may be held open by the upper portion of anactuator tube 53 that can be extended through theseat ring 52 as shown. Theactuator tube 53 has apiston section 54 that is sealingly slidable within the bore of a mainvalve actuator mandrel 55, thepiston section 54 having an upper outer diameter that is engaged byseal rings 56 and a lower, greater, outer diameter surface that carries seal rings 57. The difference in seal diameters provides an upwardly facingsurface 58 on which pressure can act tending to force the tube downwardly, and acoil spring 59 biases the tube upward. Thus theflapper element 50 is a normally-open device that can be closed by applied pressure to prevent production fluids from escaping from thepipe 26 thereabove when thecontrol unit 25 is unlatched from thevalve section 21.
Theactuator mandrel 55 has an enlargeddiameter piston section 60 that carries seals 61 which slide against an innercylindrical wall surface 62 of thelower housing section 42. Avariable volume chamber 63 is thus provided below thepiston section 60, and is arranged to contain a gaseous medium such as nitrogen under pressure. The lower end of thechamber 63 is defined by a floatingring 64 that carries inner and outer seal rings 65, 66. Thehousing section 42 is sealed with respect to theactutor mandrel 55 by aseal ring 67 located below thering 64. The lower end portion 68 of themandrel 55 extends through a reduceddiameter seal section 70 of thehousing member 42, with the seal section being sized to fit within the polish bore of theupper end section 71 of thevalve assembly 21. A series of packing seals 72 provides a fluid-tight connection.
An outer sleeve 74 on thehousing section 42 fits over the outer periphery of thevalve body section 71, and has a plurality of circumferentially spaced, radially directed windows 75 which receive laterally shiftable latch dogs orkeys 76. The inner profiles of thekeys 76 fit into an externalannular recess 77 in thebody section 71, and in the latched position shown in Fig. 2, are held in their inner positions by anannular locking surface 78 on the verticallymovable latch sleeve 80. Thesleeve 80 is biased downward by acoil spring 81 that reacts between an upwardly facing shoulder on the sleeve and a downwardly facing shoulder on amechanical release nut 82. Thenut 82 is threaded to thehousing section 42 at 83, and is splined to therelease sleeve 80 at 84. Thus should thehousing section 42 be rotated to the right by thepipe 26 relative to thesleeve 80, thenut 82 will be shifted upward along the housing and the sleeve. Ashear pin 86 is used to couple thenut 82 to thehousing section 42, so that a predetermined torque must be applied to the pipe, sufficient to shear thepin 86, before therelease nut 82 can be actuated.
Thelatch sleeve 80 has apiston section 87 at its upper end which carries aseal ring 88 that seals against a lesser diameter outer surface 89 of thehousing section 42. A greaterdiameter seal ring 90 is positioned therebelow, so that the annular region between the seal rings 88 and 90 can be pressurized to cause thelatch sleeve 80 to shift upward against the bias afforded by thecoil spring 81. When this occurs, the lockingsurface 78 is removed from behind thekeys 76 so they can shift outward to release thecontrol unit 25 from thevalve section 21.
When thecontrol unit 25 is engaged with thevalve section 21, a series of circumferentially spaced lugs 92 engage in downwardly openingslots 93 formed in the lower end portion of thelatch sleeve 80. Each slot has a helical side wall as shown to cause automatic engagement of the lugs and slots when the control unit is lowered onto thevalve section 21. The engagement of the slots with the lugs prevents relative rotation of thelatch sleeve 80 so that the release nut can be operated by rotating the pipe as previously described.
Thevalve section 21 includes avalve body 100 having atubular cage member 101 mounted for upward and downward movement therein. Thecage 101 has diametrically opposed, downwardly extending legs 102 on which aball valve element 103 is mounted by trunnion pins 104. A transverseeccentric pin 105 that is approximately fixed to thevalve body 100 engages in radially directedslots 106 in theball element 103 so that when thecage member 101 is shifted downward, the ball is rotated to an open position where itscentral bore 107 is axially aligned with theflow passage 108. Upward movement of thecage member 101 will, on the other hand, result in rotation of the ball element to its closed position where an outerspherical surface 109 thereof engages a spherical annular seat surface on aseat ring 110 carried by the cage member. Theball element 103 also is engaged by atube 111 that is biased upwardly by acoil spring 112 that may be located within acounter bore 113 formed in thevalve body 100 below the slick joint section thereof. Thespring 112 tends to force theball element 103 and thecage member 101 upwardly, to cause the ball element to close.
Aflapper valve element 115 is hinged to thecage member 101 above theball element 103, and is spring-loaded to close upwardly against aseat ring 116 that is carried by the cage. Theflapper element 115 provides a redundant closure apparatus against the flow of well production fluids from theproduction tubing 16. Theflapper element 115 is held open by a tubular "stinger" 117 that extends through theseat ring 116, and thestinger 117 is biased downwardly by thecoil spring 59. Thus theflapper element 115 also is a normally closed device to assure shut-in of the well. As will be described in greater detail below, when thecontrol unit 25 is engaged with, and latched to, thevalve section 21, the lower end portion 68 of theactuator mandrel 55 will automatically become latched to thecage member 101, so that upward and downward movement of the actuator mandrel causes corresponding longitudinal movement of the cage member.
A vent valve assembly indicated generally at 120 operates to vent excessive fluid pressures that may become trapped between theball valve 103 and theretainer valve element 50. The pressure is vented to the interior of theriser 18 prior to release of thelatch mechanism 76, and the vent valve is opened in response to the application of pressure to line C as will be described in detail below. In case of hydraulic failure, thevent valve 120 is arranged to be opened mechanically by alinkage 121 during release of thelatch keys 76 through operation of therelease nut 84 in response to rotation of thepipe 26.
Turning now to Figs. 4A and 4B for a more detailed illustration of one embodiment of the present invention, the same reference numbers will be used to describe parts mentioned above with respect to Fig. 2. As shown in Fig. 4A, which is a longitudinal half-sectional view (right side), theupper sub 40 of thecontrol unit 25 is threaded at 125 into the upper end of theupper housing section 41, and hasinternal threads 126 to which the lower pin end of thepipe 26 is threaded. The fitting for line A is sealed into a receptacle formed in the upper end of thehousing section 41, and is held in place by aretainer ring 127 and a threadedcap 128. The lower end of thesub 40 abuts theseat ring 52 which has an inwardly extendingflange 130 resting on top of asleeve 131 that is supported by, and keyed to, an inwardly directedshoulder 129 on thehousing section 41. Theseat ring 52 carries upper and lowerexternal seals 132, 133 that prevent leakage from aradial passage 134 that leads from an internal region below theflapper valve seal 135 to alongitudinal bore 136 formed in thehousing section 41.
Thebore 136 receives thevent valve assembly 120 described generally above. This assembly includes an upperdifferential area piston 138 carryingseals 139, 140, and alower valve tube 141 having apush rod 142 which extends below the lower end of abushing 143 which closes the lower end of thebore 136. The pressure of a control fluid in line A is communicated via apassage 144 to the area above the upper end of thepiston 138 so that this pressure acts downwardly on the piston. The pressure of well production fluids, which exist in thecentral passage 108 of thecontrol unit 25, is communicated via theradial passage 134, anannular area 145 outside of aguide sleeve 146 in which thepiston 138 is fitted, and theannular area 147 inside thesleeve 146, to the upwardly facingarea 148 of the piston to act downwardly thereon. Well pressure also is communicated into theannular space 149 outside of thevalve tube 141 so as to act upwardly on the tube over a resultant transverse area defined by the difference in diameter ofseals 140 and 151. Thus well pressure tends to shift thevalve tube 141 upward, and hydraulic pressure in line A tends to shift the tube downward. Sufficient upward movement of thetube 141 will position thelower seal 151 thereon above the upper end of thebushing 143 so that pressure in thepassage 134 can be vented past thepush rod 142 into the annular space outside the tool. The lower end of thepush rod 142 rests against the upper end of asleeve piston 153 that is mounted inside the upper end of thelatch release sleeve 80. Thesleeve 153 and thecap 154 at the upper end of thesleeve 80 have axially spacedshoulders 155, 156 that permit thesleeve piston 153 to shift upward by a distance sufficient to drive the vent valve tube open prior to engagement of theshoulders 155, 156 in response to the application of hydraulic control pressure to line C. The lower end of thesleeve piston 153 is engaged by aspacer ring 157 through which theshear pin 86 extends, so that a mechanical release of thelatch keys 76 in response to rotation of thepipe 26 and upward movement of thenut 84, also will drive the vent valve tube open. Thus thevent valve assembly 120 is always opened prior to disconnection of the latch mechanism by either hydraulic pressure or by mechanical means. Moreover, the well pressure within the tool biases the vent valve toward open position. Thevalve tube 141 and thepiston 138 both haveaxial passages 159, 160 for pressure equalization.
As previously mentioned, a ballvalve actuator mandrel 55 is sealingly slidable within thehousing section 41 which can include anupper member 162, anouter member 163 and aninner member 164 that rests on ashoulder 165 on the outer member and has its upper end engaged by the lower portion of the upper member. Themandrel 55 also can be constructed with several sections threaded together, including anupper section 166, acoupling section 167 and alower section 168. Thepiston member 60 can be made as a separate part and mounted on the mandrel assembly as shown in Fig. 4A. The floatingseparator ring 64 is located at the bottom of avariable volume chamber 170 and carries inner andouter seals 65 and 66. Thechamber 170 is adapted to be charged with a suitable medium such as nitrogen gas under an initial pressure, for example, of about 2000 psi. The gas acts upwardly on the lower face of thepiston 60, and also acts via aradial port 171, andpassages 172, 173 on a downwardly facingsurface 174 of theflapper actuator tube 53 so as to bias the same upwardly.
Hydraulic control line pressure acts via passage A on the upper face of thepiston 60 so as to force it and the actuator mandrel assembly downward within thehousing section 164. Such pressure also acts viachannels 175, 176, 177 and 178 on theupper surface 58 of theflapper tube 53 in order to exert downward force thereon. Thetube 53 is biased upwardly by acoil spring 59 as shown in Fig. 4B, the spring reacting between an inwardly extendingflange 179 on the lower end of theactuator mandrel section 168 and the lower end surface of thetube 53.
Control pressure applied to line B acts throughpassage 180 on the lower face of the floatingpiston 64 and thus increases the pressure of nitrogen in thechamber 170. This pressure exerts upward force on theactuator piston 60 and themandrel assembly 55 which is releasably latched to thecage member 101 in a manner that now will be described.
As shown in Fig. 4B, alatch sleeve 182 is threaded to the upper end of thecage member 101. Thesleeve 182 has a plurality of circumferentially spacedholes 183 arranged in a horizontal plane near the upper end thereof, with aball 184 being received in each hole. The lower end portion of themandrel section 168 has anenlargement 185 formed thereon, which is located above the lower end of the section by a distance such that it is below the level of theballs 184 when such lower end engages theflapper seat ring 110. The diameter of eachball 184 is larger than the wall thickness of thesleeve 182, so that when thecage member 101 is pushed downward, aninclined surface 186 on thebody 100 cams the balls inward above theenlargement 185 in order to lock the mandrel to the cage. So long as thecage 101 is in a lower position, aninner wall surface 187 holds theballs 184 inward. Thus thecage 101 must move downward with the actuator mandrel due to engagement of its lower end with theseat ring 110, and the cage is pulled upward with the mandrel by engaement of theenlargement 185 with theballs 184. When theballs 184 arrive at the location shown in Fig. 4B, they can shift outward into therecess 188 above theshoulder 186 in order to release the actuator mandrel from the cage.
Astinger tube 190 for pushing theflapper valve 115 open may be coupled to thelower section 168 of theactuator mandrel 55 byopposed pins 191 that extend intolongitudinal slots 192 in the wall of thetube 190 as shown in developed plan view in Fig. 6.Additional pins 193 on the lower end of theupper stinger tube 53 also extend intoinclined slots 194 on the upper portion of thelower tube 190. Theslots 192 and 194 are arranged such that downward movement of themandrel section 168 relative to thetube 190 will cause the tube to rotate, themandrel section 168 being keyed at 196 to aspline groove 195 in the housing section. Rotation of thetube 190 causes corresponding rotation of theupper stinger tube 53, wherebyinclined slots 197 on theupper portion 198 thereof that are engaged bypins 199 on thesleeve 131 cause upward movement of the tube and opening of theflapper element 50 as shown in Fig. 4A. Thus bothflapper elements 50 and 190 are opened mechanically as thecontrol unit 25 is latched to thevalve body 21.
Theball valve 103 and its mode of actuation have been previously described with respect to Fig. 2. Although not shown in detail in the drawings, the hanger flange 23 (Fig. 1) may be threaded to the pipe stem below the stick joint 22 so as to be adjustable therealong. A suitable key may be used to lock thehanger flange 23 in a selected position.
In operation, a production or drill stem testing tool is lowered into the well 11 on thepipe string 16 to test depth minus water depth. The subsea control valve apparatus of the present invention is then installed in the pipe string, and the hydraulic control lines A, B and C are connected to the upper end of thecontrol unit 25, along with the chemical injection line and the safety valve control line. The apparatus then is lowered through theriser 18 until the assembly is landed in theblowout preventer stack 14, with thehanger flange 23 resting on theshoulder 24. The various parts and subassemblies are in the relative positions shown in Figs. 4A and 4B, with thecage member 101 in its upper position so that theball valve 103 is closed. Thelower stinger tube 190 is extended through theseat ring 116 so that theflapper element 115 is open, and theupper stinger tube 53 is in its upper position holding theretainer valve flapper 50 open. After the apparatus is landed, the lower ones of the pipe rams are closed around the slick joint 22 to seal off the annulus between thepipe 16 and the innermost string ofcasing 13.
To open thevalve 103 so that the well can produce, the line A is pressurized from theonboard control panel 30. The hydraulic pressure from line A acts downward on the upper face of thepiston 60, forcing it and themandrel assembly 55 downward against the bias of the nitrogen gas in thechamber 170, and thecoil spring 112. Downward movement of themandrel assembly 55 causes corresponding downward movement of thecage member 101 and rotation of theball element 103 to open position. Thelatch balls 184 are shifted inwardly above theenlargement 185 so that the actuator and cage are connected together. Theball valve 103 remains open so long as pressure is applied to l ine A so that the well can produce fluids. Theretainer valve element 50, which is a normally open device, remains open as described as the well is produced.
To close theball valve 103, the pressure in line A is bled off. The combination of the pressure of the nitrogen gas in thechamber 170, and the bias of thecoil spring 112, forces thecage member 101 upward to rotate the ball closed. The upward force due to nitrogen pressure is designed to be sufficient to ensure cutting of a 15/32" logging cable should a wireline tool be in the well, and an emergency shut-in is desired. Theball valve 103 has the lower portion thereof cut away to provide for the shearing and cutting in two of any one inch coil tubing that may be disposed in the well.
To assist in closing theball valve 103, in the event further assistance is needed, pressure can be applied to line B. Such pressure enters below the floatingpiston 64 viachannel 180, and increases the pressure of the nitrogen inchamber 170 to correspondingly increase the upward force on thepiston 60 and themandrel assembly 55. Of course the increased force results in increased torque being applied to theball element 103 by the eccentric 105. The pressure in line B also passes through thechannels 175, 176, 177 and 178 and acts downward on thesurface 58 of theupper stinger tube 53. Thetube 53 is caused to shift downward against the bias afforded by thecoil spring 59 to enable theflapper element 50 to be pivoted closed by its hinge spring. The pressure of the nitrogen in thechamber 170 also will act via thepassages 171, 172 and 173 on thesurface 174. However, thesurface 174 has substantially the same transverse cross-sectional area as thesurface 58, so that force due to applied pressure in line B are balanced with respect to thetube 53. Well pressure in thecentral passage 108 through the tool acts upwardly on theactuator mandrel 53 via an area defined in part by aseal ring 200 on thehousing section 164, and downwardly thereon over an area defined in part by theseal ring 201 at the upper end of the mandrel assembly. Since these seal rings engage on substantially the same diameters, themandrel assembly 53 is substantially balanced with respect to well pressures.
The redundant valve system provided by theflapper element 115 will remain open as shown as long as thecontrol unit 25 is latched to thevalve section 21. However when thecontrol unit 25 is unlatched and disconnected from thevalve body 100, thelower stinger tube 190 will be withdrawn through theseat ring 116 to enable the flapper to be closed by its hinge spring. When closed the flapper element will shut off upward flow, even though theball element 103 might be stuck in its open or partially open position.
Unlatching and disconnection of the control unit is accomplished by pressurizing line C. Such pressure acts upwardly on the difference is areas circumscribed by therings 88 and 90 that seal thesleeve piston 153, thereby causing it to move upwardly. The initial upward movement of thesleeve 153 pushes thevent valve tube 141 upward to disengage itsseal 151 from thebushing 143 and allow any excessive pressure trapped between theball valve 103 and theretainer flapper 50 to be vented to the annulus outside thecontrol unit 25. Additional upward movement of thesleeve piston 153 lifts thelatch sleeve 80 upward to remove the locking surfaces 78 from behind thelatch keys 76. When thesurfaces 78 have cleared thekeys 76, they are free to shift outwardly in the windows to released position with respect to thevalve body groove 77. Upward force of thelatch sleeve 80 overcomes the bias of thespring assemblies 81 which continuously urge the sleeve downwardly. With thekeys 76 released, thecontrol unit 25 can be pulled upwardly by thepipe string 26, causing thehousing seals 72 to be withdrawn from the bore of theupper body section 71. As thecontrol unit 25 is lifted, thelower stinger tube 190 is pulled out of theflapper seat ring 116 to allow the flapper to close upwardly against its seat. With thecontrol unit 25 removed, thevalve section 21 is of such short length that the blind rams of the upper ram-type preventer can be closed against one another to ensure complete control of the well.
To prevent dumping of well fluids in thepipe string 26 into theriser 18, line B can be pressurized to cause downward shifting of theupper stinger tube 53 as previously described. The retainer valve accelerates the disconnection procedure for thecontrol unit 25 by suppressing or eliminating the requirement to bleed off pressure in thepipe string 26 prior to disconnection. Theretainer flapper 50 also can be closed to enable pressure-testing the entireupper pipe string 26 prior to initiating a production or drill stem test.
In case it should become necessary to effect a mechanical release of thecontrol unit 25, thepipe 26 can be rotated at the surface to cause corresponding rotation of thehousing section 42. When theshear ring 86 is disrupted in response to a predetermined torque, continued rotation causes thenut 84 to lift thelatch sleeve 80 upward to the released position. Prior to actual upward movement of thesleeve 80, thevent valve tube 141 will have been pushed open to vent pressures between theflapper valve 50 and theball valve 103.
To reconnect thecontrol unit 25, a procedure similar to the disconnection procedure outlined above is used. Thecontrol unit 25 is lowered through the riser with the line C under pressure to hold thelatch sleeve 80 in the upper position. When thekeys 76 encounter the outer inclined surface on the upper section of thevalve body 100, the keys are cammed outwardly and positioned opposite thebody recess 77. Thus as the pressure in line C is bled off, thesprings 81 shift thelatch sleeve 80 downward to its position where thekeys 76 are locked within thebody recess 77. The reconnection procedure also causes thelower stinger tube 190 to push theflapper 115 open, and the retainer flapper remains in its normally open position until such time as pressure is applied to line B.
Another embodiment of the present invention is illustrated in Figs. 5A-5C. This embodiment is generally similar to the previously described embodiment in overall arrangement, but has other unique features as will be described herein. The valve system includes aretainer valve assembly 250, a hydraulically operablevalve actuator assembly 255 and a well shut-invalve assembly 260 that is releasably connected to the actuator assembly. The actuators for the retainer valve and the redundant valve element in the shut-in section are not mechanically connected as in the case of the previous embodiment, so that when line B is pressurized the redundant valve element in the shut-in section closes, and the last valve element to close in the operating sequence is the retainer valve element. In this manner, malfunction of one valve closure system or any component thereof does not affect the operation of the other valve closure system.
As shown in Fig. 5A, theretainer valve body 280 has asleeve piston 281 slidably disposed in the lower portion thereof. Thesleeve piston 281 is connected to a generally tubularvalve cage member 282 which carries aseat ring 283 and two oppositely disposed, upwardly extendingarms 284 on the upper end thereof. Aball valve element 285 is mounted for pivotal rotation on the arms by means of trunnion pins 286, and has radially directedslots 287 through the side walls thereof. Ayoke 288 that is threaded to theupper sub 290 has a downwardly extendingleg 291 with oppositely extendingeccentrics 292 on its lower end which engage therespective slots 287, so that upward movement of the ball valve element relative to the yoke causes the ball to rotate in one direction, and downward relative movement causes rotation in the opposite direction. Acoil spring 293 which reacts between an upwardly facingshoulder 294 of aseal sleeve 295, and downwardly facingshoulders 296 on oppositely directed flanges 297 (shown 90° out of position for ease of illustration) which are formed on the upper ends of thecage arms 284, forces thecage member 282 upwardly within thevalve body 280 to normally maintain the ball valve in its open position as shown in Fig. 5A.
Apressure channel 300 that extends upwardly within thelower section 301 of thebody 280 has its upper end in communication with an upwardly facingsurface 302 on thesleeve piston 281, so that hydraulic control pressure that is applied to this channel produces downwardly directed force to the sleeve piston, causing it and thecage member 282 to shift downward against the bias afforded by thecoil spring 293. Thechannel 300 is in communication with line B as in the previously described embodiment. This motion closes theball 285 so that its spherical outer surface engages theseat ring 283. Asecond pressure channel 303 which also extends upwardly in thelower portion 301 of the body 280 (and is circumferentially offset from the other channel) feeds applied pressure to a downwardly facingsurface 304 which causes thesleeve piston 281 and thecage member 282 to be forced upwardly. Thechannel 302 is connected to line A as in the previously described embodiment. Such upward movement, which is aided by the force of thecoil spring 293, causes theball valve 285 to open. Thus it will be apparent theball valve element 285 which constitutes a retainer valve is normally open under the influence of the coil spring, that the valve can be held open with pressure applied to line A, and that the valve is closed in response to the application of pressure to line B.
Seal rings 305 and 306 engage on different internal diameters of thebody section 301, as shown, to provide the piston effect. Theseal sleeve 295 also carries seal rings 307 and 308 which prevent leakage of control line fluid from the upper end ofchannel 300. Thelower end portion 301 of theretainer body 280 is threaded at 310 into theupper end portion 311 of the hydraulicallyoperable actuator section 255, and theupper sub 290 hasthreads 311 for connection to the lower end of the section ofproduction pipe 26 that extends upwardly to thevessel 10.
Turning now to Fig. 5C, the shut-invalve section 260 includes a generallytubular valve body 320 having alatch section 321 at its upper end. Avalve cage member 322 is slidably disposed within thevalve body 320, and has anupper portion 323 which carries aseat ring 324 and aflapper valve element 325. The lower portion of thecage 322 carries anotherseat ring 326 and has diametrically opposed, downwardly extendingarms 327 on which aball valve element 328 is mounted by trunnion pins 329. A suitable window is formed in the side of thecage 322 below theupper seat ring 324 to receive theflapper element 325 in its open position as shown in the drawing. Acoil spring 330 reacts between ashoulder 331 on thebody 320 and ashoulder 332 on the lower portion on thecage member 322, and tends to force the cage upwardly within the valve body.
Ayoke 335 is threaded to thelower end portion 336 of thevalve body 320, and as shown in Fig. 9 has anupstanding leg 337 with oppositely extendingeccentrics 338 that engage in radially directedslots 339 in opposite side walls of theball valve element 328 which is shown in further detail in Figs. 7 and 8. Thus downward movement of thecage member 332 within thebody 320 will cause theball element 328 to rotate to its open position where thebore 340 thereof is axially aligned with theflow passage 341 through the valve body, whereas upward movement of the cage member will cause the ball element to rotate to closed position where its sphericalouter surface 342 engages theseat ring 326. As shown in Fig. 8, theball element 338 is opened on the side thereof opposite thesurface 342 to facilitate the cutting of wireline or coil tubing as will be apparent to those skilled in the art.
Alatch tube 345 is threaded into theupper end portion 323 of thecage member 322, and has circumferentially spacedwindows 346 that received laterally movable latch dogs orkeys 347. The lower end of thelatch tube 345 retains theflapper seat ring 342 on thecage member 323. An externalannular latch recess 350 is formed on the outside on thelower end portion 351 of a latch tube 352, the recess being shaped to receive the inner portions of thekeys 347. The lower end surface of the tube 352 is arranged to abut against theseat ring 324 in order to drive thecage member 322 downward. When this occurs, the keys 348 are locked in engagement with therecess 350 by aninner surface 353 so that subsequent upward movement of the latch tube 352 will function to pull thecage member 322 upwardly.
Aninternal pressure channel 360 extends substantially throughout the length of thevalve body 320 so that the chemicals can be injected into the production string below the valve assembly to inhibit the formation of hydrates (ice) that might block valve operation, or to provide a fluid pressure channel for the remote control of a surface controlled, subsurface safety valve that is located in the production string downhole. The upper end of thechannel 360 terminates in aradial port 361 which enters the seal bore 362 of theupper portion 363 of the body at a location that is straddled by the seal packing 364 on the lower end of theactuator section 255.
Theflapper valve 325, which tends to close against theseat ring 324 due to the action of ahinge spring 365, is arranged to be pushed open by inserting through the seat ring a "stinger" 369 that pivots and then holds the flapper element open. Theball valve element 328, which also is a normally closed device, is opened by shifting thecage member 322 downwardly within thebody 320, against the bias afforded by thecoil spring 320, so that theeccentrics 338 on theyoke 337 cause theball 328 to pivot in a counter clockwise direction about thepins 329 to bring its central opening into vertical alignment with the flow passage of thevalve body 320.
The hydraulically operablevalve actuator section 255, which is connected directly to thelower end portion 301 of theretainer valve body 280, includes an elongatedtubular housing assembly 370 having a reduceddiameter seal section 371 at its lower end as shown in Fig. 5B. The flapper valve actuator tube or "stinger" 369 is slidably mounted within thehousing 370, and a ball valve actuator mandrel is slidably mounted in the housing assembly externally of theactuator tube 369.
The ball valve actuator mandrel comprises anupper piston section 374 that carriesseal ring 375 on a lesser outer diameter thereof, and additional seal rings 376 on a greater outer diameter thereof. A pressure channel A leads to anannular chamber 377 whose inner and outer diameters are defined by the seal surfaces of the housing engaged by the seal rings 375 and 376, so that hydraulic fluid pressure applied to channel A forces theactuator mandrel 372 downward within thehousing 370.
Anannular channel 380 in thehousing 370 below thepiston section 374 has its lower end closed by a floatingpiston ring 381 that carries inner andouter seals 382 and 383, and the chamber is communicated with a channel B by a radial port as shown, so line B pressure acts on thelower face 384 of thesection 374. Thecentral section 385 of theactuator mandrel 372 has an outwardly directedflange 386 that carries seals 387 which engage an inner wall surface of thehousing 370 on a lesser diameter than that engaged by theseals 376. Theannular space 388 between the floatingring 381 and theflange 386 is adapted to contain air at atmospheric or other low pressure. A thirdannular chamber 390 located below theflange 386 has its lower end closed byseals 391 which engage on a lesser diameter of themandrel section 385 than the flange seals 387. Thechamber 390 is adapted to contain a compressible medium such as nitrogen gas under pressure which exerts upward force on thelower face 392 of theflange 386.
Theupper section 395 of the "stinger"tube 369 has three sets of seal rings 396,397, 398, with theupper seals 396 engaging thepiston section 374, and the middle andlower seals 397, 398 engaging theintermediate section 385 of theactuator mandrel 372. The middle seals 397 engage on a greater inner diameter of the actuator mandrel than theupper seals 396 to provide a resultant, upwardly facingsurface 399 on the stinger tube that is subject to the pressure of nitrogen viapassages 400 and 401. The middle seals 397 also engage on a greater diameter than the lower seals to provide a resultant, downwardly facingsurface 402 on the stinger tube that is subject to the pressure of line B viaports 403 and 404 and a longitudinal channel (not shown). Thus the stinger tube is biased downward by nitrogen pressure, and can be forced upwardly through application of hydraulic control pressure to line B. Thelower section 351 of theactuator mandrel 372 may be formed as a separate sleeve, as shown, which is threaded to thesection 385 at 406, with the thread being locked by apin 407.
In order to provide a releasable latch connection between thecontrol unit 255 and the shut-invalve section 260, alatch sleeve 410 is slidably mounted on the outside on thehousing 370, and has a lockingsleeve 411 threaded to its lower end as shown in Fig. 5C. The locking and latchsleeves 411 and 410 are biased downward by a plurality ofspring assemblies 412 that are mounted in axial bores on adog sleeve 413 that has its upper end threaded to the housing at 414. Thedog sleeve 413 has a plurality ofwindows 415 near its lower end which receive laterally shiftable dogs orkeys 416. Thekeys 416 can engage in theannular recess 417 on theupper section 321 of thevalve body 320, and are held inwardly in locked positions by aninner locking surface 418 on the lockingsleeve 411. When the lockingsleeve 411 is moved upward relative to thedog sleeve 413, an enlargedinner diameter 414 of the sleeve is positioned behind thekeys 416 to enable them to move outward and release from therecess 417.
In order to actuate thelatch sleeve 410, asleeve piston 425 is slidably mounted on thehousing 370 inside the upper end portion of the latch sleeve. Pressure applied to the differential area of thesleeve piston 425 defined by upper and lower seal rings 426, 427 via channel C in the housing causes the sleeve piston the shift upward, and, after engagement with cup 428 at the upper end thereof to drive the latch sleeve upward to it key- release position. When pressure in line C is relieved, thespring assemblies 412 force thelatch sleeve 410 downward to its key-locked position. As a redundant or back-up means to release thekeys 416, aclutch nut 430 that is threaded to thehousing 370 by large acme-type threads 421 is provided. Thenut 430 is splined to the latch sleeve at 432, and normally is held against rotation with respect to thehousing 370 by ashear pin 433. If hydraulic control line pressure fails to release thelatch keys 416 as described above, theentire housing 370 of thecontrol unit 255 can be rotated to the right by turning theproduction pipe 26 at thevessel 10. Thelatch sleeve 410 is held against rotation due to engagement of downwardly openingslots 435 in the lower end of the locking sleeve 441 with outwardly projectinglugs 436 on the shut-invalve body 320. Applied torque causes thepin 433 to be sheared. Additional rotation then causes thenut 430 to feed upwardly along thehousing 370, thereby driving thesleeve piston 425 and thelatch sleeve 410 upwardly until thekeys 416 are released.
In order to ensure that excessive pressure is not trapped within the tool between the shut-invalve unit 260 and thecontrol unit 255, avent valve assembly 450 is provided as shown at the top of Fig. 5B and the bottom of Fig. 5A. Abore 451 formed in an upper outer portion of thehousing 370 receives avent valve tube 452 which carries upper and lower seal rings 453, 454, and has apush rod section 455 at its lower end. Theseals 453, 454 normally span aradial vent port 456 which communicates with theflow passage 341 of the tool via a lengthy vertical port (not shown) in thehousing 370 and alower port 457 therein. Thetube 452 has acentral port 458 to equalize fluid pressure thereacross. Acompensator piston 460 is movable in the top of the bore, and functions to separate line A pressures, which enter the housing atconnection 461, from riser fluids which are present in thebore 451 below the piston.
Normally, thevent valve tube 452 occupies the position shown in Fig. 5B with itspush rod 455 resting against ashoulder 462 on thehousing 370. In this position theseals 453 and 454 close off thevent port 456, and in response to line A pressure, thecompensator piston 460 shifts downward and positively holds the vent valve tube closed. However when thesleeve piston 425 is shifted upward in response to pressure in line C, theupper end surface 462 of the piston pushes the valve tube upward until itslower seal 454 clears thevent port 456, which occurs prior to engagement of the piston with the latch sleeve cap. Thus internal pressure is always vented to the riser annulus prior to unlatching to the control unit from the shut-in valve unit.
Another unique feature of the present invention is the provision of fluid passages in various components of the tool which ensure that should a dynamic seal that is exposed to well fluid pressure leak for any reason, the well pressure is channeled into line B to provoke closing of the valve. As shown in Fig. 5A, for example, a pressure channel in the form of alongitudinal port 500 leads from the region of thesurface 302 to aradial port 501 that opens to the outside of thesleeve piston 281 at a location beween the seal rings 306. Should the lower one of theseals 306, which is a dynamic seal that is exposed to well pressure in theflow passage 341, leak or otherwise fail to hold pressure, such well pressure will enter theport 501 and pressurize thechannel 300. Thechannel 300 is connected to line B by virtue ofradial ports 502 that extend between seals 503 (Fig. 5B). Another dynamic seal subject to well pressure is the upper one of theseals 375 at the upper end of theactuator mandrel 372. Should this seal leak, well pressure would then pass throughport 502 and intochannel 300 which is connected to line B. A similar structure is present in connection with theupper seal 396 on thestinger tube section 395. Should this seal leak, well pressure will be fed to alongitudinal port 504 that has its lower end placed in communication with channel B. Aradial port 505 is provided to feed well pressure to line B in the event the lower one of theesals 391 should leak. Finally, if theseal 398 on thetube section 395 should leak, well pressure can pass through theclearance space 506 and be communicated with line B in the same manner asport 504.
Various ones of the vertical, radial and other ports and passages are shown in phantom lines in the drawings for convenience of illustration, of course it will be apparent that these passages are not located in the plane of the cross-section shown in the drawings, but rather are circumferentially spaced from such plane.
The overall operation of the embodiment shown in Figs. 5A-5C is essentially similar to that described with respect to the previous embodiment, and thus will not be repeated in detail. Such operation may be summarized as follows. The application of hydraulic fluid control pressure to line A produces these functions:

1. the well shut-inball valve 328 is opened; and
2. thecompensation piston 460 is forced down against thevent tube 452 to insure closure ofvent port 456.

Application of pressure to line B performs the following operations:

1. theretainer valve 285 is closed;
2. the shut-inball valve 328 is assisted in closing.

When control line C is pressurized, the following operations occur:

1. thevent valve 452 is opened to vent interior pressure, after which
2. the latch dogs 416 are released to unlatch the control unit and shut-in valve unit.

Claims

1. Apparatus adapted to be landed in a subsea wellhead and used to control the flow of fluids therefrom, comprising:

-a relatively short length valve body (100) having a flow passage;

-first, normally closed valve means (103, 115) for opening and closing said flow passage;

-a control unit (25) having a flow passage and being adapted to be connected to a pipe string (26) extending upwardly to the surface;

-remotely operable means (76) for releasably connecting said control unit (25) to said valve body (100);

-second, normally open valve means (50) in said control unit for retaining fluids in said pipe string when said connecting means is released; and

-means (80) responsive to the application of a hydraulic control pressure (line C) to an interior region of said control unit (25) for releasing said connecting means;
characterized by vent passage (134, 136) and vent valve means (120) that are opened in response to the application of said hydraulic control pressure for bleeding any excessive pressure between said first (103, 115) and second (50) valve means to the exterior of said control unit prior to release of said connecting means.

2. The apparatus of claim 1 further including means (144, 138) for preventing opening of said vent passage and vent valve means (120) so long as said first valve means (103, 115) is open.

3. The apparatus of claim 2 further including passage means for transmitting well pressure to cause closing of said vent passage and vent valve means (120) in the event of leakage of a seal ring that is exposed to well pressure.

4. The apparatus of claim 1 further including axial cam means (82) responsive to rotation of said pipe string (26) with respect to said valve body (100) for releasing said connecting means (76), and means responsive to operation of said axial cam means (82) for driving said vent valve means (120) to its open position.

5. The apparatus of claim 4 further including shear means (86) for preventing operation of said axial cam means (82) until a torque of a predetermined magnitude has been applied to said pipe string (26).

6. The apparatus of claim 1 further including injection passage means (45) extending through said control unit (25) and a portion of said valve body (100) for enabling selective injection of a chemical into said flow passage below said second valve means (50).

7. The apparatus of claim 1 further including control fluid passage means (46) extending through said control unit (25) and said valve body (100) for enabling a hydraulic control pressure to be applied for operating an auxiliary safety valve means (47) located in the pipe string below said first valve means (103, 115).

8. The apparatus of any one of claims 1 to 7 wherein said first valve means (103, 115) comprises a ball valve element (103); cage means (101) for mounting said ball valve element for rotation about an axis (104) that is transverse to said flow passage, said cage means being mounted for longitudinal movement in said valve body; and eccentric means (105) fixed to said valve body (100) and cooperable with said ball valve element (103) to rotate the same to the closed position when said cage means (101) is moved upward and to rotate the same to the open position when said cage means is moved downward.

9. The apparatus of claim 8 wherein said first valve means (103, 115) further includes a flapper valve element (115) hinged to said cage means (101) for pivotal rotation between an open position to the side of said flow passage and a closed position transverse to said flow passage.

10. The apparatus of any one of claims 1 to 9 wherein said second valve means (50) comprises a second flapper element (50), and an upwardly facing seat (52), said second flapper valve element (50) being mounted on said control unit (25) for pivotal movement between an open position to the side of said flow passage and a closed position against said seat.

11. The apparatus of claim 10 wherein said second valve means (50) includes an actuator tube (53) mounted for movement axially of said control unit (25) between an upper position extending through said valve seat (52) and holding said flapper element open, and a lower position withdrawn from said seat (52) to enable said flapper valve element (50) to close.

12. The apparatus of claim 8 further including an actuator mandrel (55) in said control unit (25) movable upwardly and downwardly therein; piston means (60) on said actuator mandrel (55) sealingly slidable in cylinder means (62) in said control unit; and means responsive to the application of a second hydraulic control pressure (line A) to said piston means (60) for moving said actuator mandrel (55) downwardly to cause corresponding downward movement of said cage means (101).

13. The apparatus of claim 12 further including cam means (191, 192, 197, 199) on said actuator mandrel (55) and said actuator tube (53) for causing upward movement of said tube (53) in response to downward movement of said mandrel (55).

14. The apparatus of any one of claims 1 to 7 wherein said second valve means comprises a second ball valve element (285); cage means (282) for mounting said second ball valve element (285) for rotation about an axis that is transverse to said flow passages, said cage means (282) being mounted for longitudinal movement in said control unit (255); and eccentric means (292) fixed to said valve body and cooperable with this ball valve element (285) to rotate the same to open position when said cage means (282) is moved upward, and to rotate the same to closed position when said cage means is moved downward.

15. The apparatus of claim 14 further including bias means (293) tending to cause upward movement of said cage means (282).

16. The apparatus of claim 15 wherein said cage means (282) has piston (281) thereon that is sealingly slidable within cylinder means in said control unit, said piston means (281) having an upwardly facing transverse surface that is subject to a hydraulic control pressure (line B) whereby said control pressure may be used to overcome said bias means (293) and cause downward movement of said cage means (282).

17. A method for use in the production testing of a well using a control unit (25) releasably connected to a valve unit (21) landed in a subsea wellhead, said valve unit (21) having a normally closed shut-in valve (103, 115), and said control unit (25) having a normally open retainer valve (50), comprising the steps of: opening said shut-in valve (103, 115) and retainer valve (50) venting pressure in the interior of said control unit (25) between said shut-in valve (103, 115) and said retainer valve (50) to the annulus; and then releasing said control unit (25) from said valve unit (21) to enable said control unit to be removed from said wellhead.